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Abstract:

This investigation completed the verification of a
three-dimensional resin
transfer molding/resin film infusion (RTM/RFI) process
simulation model. The
model incorporates resin flow through an anisotropic carbon
fiber preform, cure
kinetics of the resin, and heat transfer within the
preform/tool assembly.
The computer model can predict the flow front location,
resin pressure distribution, and thermal profiles in the
modeled part.

The formulation for the flow model is given using the
finite element/control volume (FE/CV) technique based on
Darcy's Law of creeping flow through a porous media. The
FE/CV technique is a numerically efficient method for
finding the flow front location and the fluid pressure.
The heat transfer model is based on the three-dimensional,
transient heat conduction equation, including heat
generation. Boundary conditions include specified
temperature and convection.
The code was designed with a modular approach so the flow
and/or the thermal
module may be turned on or off as desired. Both models are
solved sequentially
in a quasi-steady state fashion.

A mesh refinement study was completed on a one-element
thick model to determine
the recommended size of elements that would result in a
converged model for a
typical RFI analysis. Guidelines are established for
checking the convergence
of a model, and the recommended element sizes are listed.

Several experiments were conducted and computer simulations
of the experiments
were run to verify the simulation model. Isothermal,
non-reacting flow in a
T-stiffened section was simulated to verify the flow module.
Predicted
infiltration times were within 12-20 percent of measured
times. The predicted
pressures were approximately 50 percent of the measured
pressures. A study was
performed to attempt to explain the difference in pressures.

Non-isothermal experiments with a reactive resin were
modeled to verify the
thermal module and the resin model. Two panels were
manufactured using the RFI
process. One was a stepped panel and the other was a
panel with two `T'
stiffeners. The difference between the predicted
infiltration times and the
experimental times was 4 to 23 percent.

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